Contents. Regular Features. Pumps, Actuators & Valves. Plant Maintenance & Risk Analysis. Special Report. Petrochemicals

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3 6 4 8 Contents Regular Features 3 Comment by Dr Kevin Harding, Senior Lecturer and Researcher in the IMWaRU (Industrial and Mining Water Research Unit), School of Chemical & Metallurgical Engineering at the University of the Witwatersrand, Johannesburg, South Africa 4 Cover story: The importance of neural network technology in reliable flame detection by Shankar Baliga, manager for research and development at General Monitors (a subsidiary of international safety company MSA), Lake Forest, California, USA 29 ICCT/SAIChE Conference July 1 August 35 Et cetera 36 Et cetera/sudoku No 92 and solution to No 91 Special Report 6 Just when you thought Eskom s failure was our only energy crisis South Africa is proving absolutely incapable of passing clear and decisive legislation which companies need to ensure clarity for their investment decisions. That uncertainty be it in mining, refining, or manufacturing is seeing investment go elsewhere by Gavin Chait Petrochemicals 8 Effects of biodiesel on plastics An understanding of the compatibility of biodiesel fuels on various plastics is essential to avoid unexpected failures and to help to ensure that this important resource does not gain a reputation for damaging plastic parts. by David Grewell, Tong Wang, Melissa Montalbo-Lomboy, Linxing Yao, Iowa State University, and Ames, IA, Paul Gramann and Javier Cruz, The Madison Group, Madison, WI 15 Focus on petrochemicals Pumps, Actuators & Valves 18 Why you should choose your valves carefully A comparison of available solenoid valves This article contains an introduction to valve technologies, what you need to know about poppet valves, piston spool valves and the cartridge principle, and how to decide which valve type suits your requirements best. by Philipp Wahl, Marketing Concepts, Festo AG & Co KG 24 Focus on pumps, actuators & valves Plant Maintenance & Risk Analysis 30 Management of change A tool for systematically managing the safety effects of change Unmanaged change can and has posed risks to hazardous processes. Many accidents, in many countries including South Africa, have occurred because of uncontrolled changes to processes, equipment, administrative systems, control systems and aspects of people and organizations. A formal system is required to manage change and/ or modifications. by Rod Prior, MD, SHExcellence, Johannesburg, South Africa 34 Focus on plant maintenance & risk analysis Transparency You Can See Average circulation (Oct Dec 2013) Paid: 49 Free: 3664 Total: 3713 Chemical Technology is endorsed by The South African Institution of Chemical Engineers and the Southern African Association of Energy Efficiency DISCLAIMER The views expressed in this journal are not necessarily those of the editor or the publisher. Generic images courtesy of

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5 Comment Accounting for water use in process industries by Dr Kevin Harding, Senior Lecturer and Researcher in the IMWaRU (Industrial and Mining Water Research Unit), School of Chemical & Metallurgical Engineering at the University of the Witwatersrand, Johannesburg, South Africa Published monthly by: Crown Publications cc Crown House Cnr Theunis and Sovereign Streets Bedford Gardens 2007 PO Box 140 Bedfordview 2008 Tel: (011) Fax: (011) Website: Publisher: J Warwick Editor: Glynnis Koch BAHons, DipLibSci (Unisa), DipBal (UCT) Consulting editor: Thoko Majozi PrEng PhD (UMIST), MScEng (Natal), BScEng (Natal), MASSAf, FWISA, MSAIChE Design & layout: Anoonashe Shumba BTech Hons Creative Art (CUT-Zim) Advertising: Brenda Karathanasis Circulation: Karen Smith Subscriptions: Wendy Charles Printed by: Tandym Print - Cape Town Subscriptions: R380 (incl. VAT) per annum Postage extra outside RSA With all the rain parts of the country experienced in March, it may slip some people s minds that South Africa is generally a water scarce country. However, over the last few years, industry has started to increase its focus on quantifying water use; including calculations on the quality of the water it discharges, in an effort to make the most of what is available and to act in a responsible manner. One of the methods to determine the impacts of water use, which is gaining popularity worldwide, is the Water Footprint. This was developed by the Water Footprint Network (Hoekstra and colleagues) in 2008 as a tool to determine how much water the full life cycle of a product or process uses. The idea was also to account for where the water might end up. For instance, South Africa exports a large amount of grapes, which results in a large volume of water leaving in the fruit. The method breaks water into Green, Blue and Grey water. Roughly speaking this is rain/ evaporation, process water and polluted water needing treatment, respectively. Since most industrial processes (during manufacturing and processing at least) do not include agricultural aspects, the Water Footprint reduces to a Blue and Grey Footprint. As such it may not be as useful as when looking at agriculture and regional water use. The benefit of determining the water usage of a process or product is that it is possible to determine its water intensity. It is reported that a cup of coffee uses 140 litres of water while wine uses 120 litres per glass (global average). This should not be misconstrued as only the process water, as the agricultural demand is also taken into account together with the water needed to purify any dirty process water to suitable local water quality guidelines. Further, the definitions of Green/Blue/ Grey have been modified slightly over the years making comparisons tricky if taken without full understanding of further details. Knowing numbers like this may feel pointless in isolation, but, when such an intensity can be compared over comparable products (for example apple vs grape juice), a more informed consumer purchase can be made or industrial comparisons understood (for example processing with catalyst A vs B). While other potentially more appropriate methods are available (LCA, water balance, WULCA etc) for specific uses, a common standard is needed to ensure quality across studies and within individual methods. As such, the International Organisation for Standardization (ISO) is developing the ISO14046 standard (Water Footprint Principles, Requirements and Guidelines). This will ensure a common framework and ensure quality as was done for Carbon Footprinting. At the University of the Witwatersrand, the Industrial and Mine water Research Unit (IMWaRU) in the School of Chemical and Metallurgical Engineering, is looking at Water Footprints and LCA studies on several mine sites, as well as for the paper industry and several other industries in South Africa. If a benchmark can be set, the opportunity exists to reduce a process water intensity both in the Blue and Grey footprints. 3

6 The importance of neural network technology in reliable flame detection by Shankar Baliga, manager for research and development at General Monitors (a subsidiary of international safety company MSA), Lake Forest, California, USA Chemical and safety engineers are continually researching new technologies in order to maximize operations and profits, while reducing risks. Part of this process is to avoid loss of valuable equipment and inventory from the destruction of an undetected fire or the complete shutdown of an entire facility resulting from a false fire alarm. These are both costly scenarios that no company wants to encounter, particularly when there are preventative measures available to avoid such catastrophes. However, choosing the best flame detection technology to protect personnel, facilities and other key investments is a time-consuming consideration. Groundbreaking neural network technology (NNT) in multi-spectral infrared (MSIR) flame detection is the latest and most innovative option for fire detection risk management. What is Neural Network Technology? Neural networks are essentially mathematical models that are inspired by biological neural networks, otherwise known as the human brain. In artificial neural networks, an interconnected group of artificial neurons process information and change structure during a learning phase. This allows the network to model complex relationships in the data delivered by sensors in a quick search for patterns, as illustrated in Figure 1. Computer researchers began efforts to apply the workings of the human brain to computers as far back as the 1940s. At that time, a neuroscientist and a logician teamed up to create the first conceptual model of an artificial neural network to solve certain kinds of problems that were easy for humans but difficult for computers. This approach is well-known today as pattern recognition. Neural networks have progressed and are used in a wide range of standard uses, many of which are at work in the FlameGard 5 MSIR detector from MSA. They include: Pattern recognition Signal processing that filters out irrelevant data Controls that manage decisions Soft sensors that analyse a collection of numerous measurements Anomaly detection the ability to generate output when something occurs that doesn t fit specific patterns, thus issuing alerts when something is out of place. At its core, NNT is an artificial intelligence. One of the key elements behind this technology is its ability to learn. It learns through a type of apperceptive process, whereby the comprehension or assimilation of something such as a new idea can be related in terms of previous experiences or perceptions. NNT operates similarly and is much like a human mind in the way that it enables a person to recognize a face from the distant past. For example, the brain facilitates recognition by matching a face with an image stored as a memory. Much like our human brain, the MSIR flame detector features thousands of pieces of data stored in its memory from hundreds of flame and non-flame patterns that it has observed in the past. It has been trained to recognize a flame based upon that data, and makes decisions about whether it is seeing an actual flame, even if it has not seen that exact pattern in the past. Greater range and field of view: fewer detectors, lower cost The FlameGard 5 MSIR flame detector combines a complex sensor array with highly intelligent neural network processors to provide new pattern recognition abilities, as it has been trained to differentiate between real threats and normal events. MSIR technology allows area coverage up to six times greater than that of more conventional ultraviolet infrared (UV/ IR) flame detectors. MSIR technology performs under various environmental conditions and offers faster response times and increased detection distances, as illustrated in Figure 2. The FlameGard 5 MSIR relies on a four sensor array to 4

7 Cover Story detect flame and non-flame events. The four sensors sample unique IR spectral wavelengths and convert those signals into a digital format to extract time and frequency data. Four sensors provide more data, increased detection distances, excellent immunity to false alarms, faster response times and better performance under various environmental conditions. The data acquired by the four sensors is automatically conveyed to the neural network where the real work of determining the threat level is done. By providing a longer range and a wider field of view, fewer detectors are needed to cover a larger territory, which reduces the cost of protection. The FlameGard 5 MSIR detector reliably differentiates between real fire threats and common activities like random motion, modulation of heated surfaces, hot air flow, reflection off water surfaces, lightning and arc welding, to name a few. Improved safety and savings The inherent differences available with the FlameGard 5 MSIR flame detector lie in the marriage of a state-of-the-art artificial neural network and sophisticated sensor arrays. This flame detector can discover fire threats faster, and at greater distances, than any other product of its kind. This, combined with superior false alarm immunity, makes protection from both fire and false alarms possible. For industries such as chemical, petrochemical and other large-scale manufacturing facilities, the end result is improved safety together with substantial savings. z Figure 1 Figure 2 Dr Baliga holds a PhD in physics from Ohio State University, and is currently responsible for the development of new sensing technologies for gas and flame detection. General Monitors is a leader in the development and manufacture of high tech gas monitoring and flame detection instrumentation worldwide. MSA will be exhibiting at OSH Expo Africa from May 2014, at Gallagher Convention Centre, Gauteng. Contact MSA Africa on or info.za@msa.safety.com Figure 3 Figure 1: Simplified view of a neural network Figure 2: Multi-spectral IR flame detection offers the longest distance protection and superior false alarm immunity. Figure 3: The FlameGard 5 MSIR flame detector 5

8 Just when you thought Eskom s failure was our only energy crisis by Gavin Chait South Africa is proving absolutely incapable of passing clear and decisive legislation which companies need to ensure clarity for their investment decisions. That uncertainty be it in mining, refining, or manufacturing is seeing investment go elsewhere. In 2008, as Eskom s failure to invest in productive capacity was devastating the economy through rolling load shedding, another group of energy producers was debating the future. The South African government was considering bringing in higher fuel standards for low sulphur emissions. Prevailing standards were based on Euro II, which permitted 500 ppm sulphur fuels, while Euro IV requires 50 ppm. Adding to the uncertainty was that Euro V permitting only 10 ppm was then being implemented in Europe. Vehicle manufacturers were already producing compliant transmissions systems for the export market but none of these vehicles could be sold locally without modification. The National Association of Automobile Manufacturers (NAAMSA) was projecting vehicle sales growth of 3% which meant that, by 2017, there would only be about 1,43 million vehicles potentially able to take advantage of low-sulphur fuels relative to 11,41 million unmodified vehicles. Should refiners invest in conversion, or should they hold fire? While the product itself is relatively cheap, requiring high volume sales to make up the overall value of the industry, the capital costs of refining capacity are extremely large. Normally, any capital expenditure can be recouped through passing the cost into the overall selling price of their products. However, in a price-controlled market, this is not possible. The cost of refurbishing crude oil refineries was estimated at about R8 billion each for each of the four refineries, R32 billion in total. The synfuels plants would also have to have some refurbishment but probably not to the same cost level, approximately R500 to R800 million. Neither would the refurbishments have any impact on productive capacity. The US Energy Information Agency estimates that South Africa s total oil consumption was bbl/d in The petroleum consumed in South Africa comes mostly from its domestic refineries that import crude oil and its CTL and GTL plants, they write. The country also imports petroleum products. In 2012, South Africa imported bbl/d of petroleum products, according to the South African Revenue Service as published by Global Trade Atlas (GTA). That trade deficit is the equivalent of the Caltex refinery in Cape Town. I was, in 2008, commissioned to write a report on the various scenarios which may play out to 2017, when government s legislation (whatever it would be) was expected to be implemented. Ultimately, whether a sovereign government issues bonds or a private company raises equity or debt for such capital-intensive investment, the funds are likely to be raised globally. This automatically creates a balance of trade concern, where cash investments must be offset by exports of products and services in order to ensure economic growth. Imports of cash (borrowings) must result in productive investments or inflation will become systemic, I wrote. Even in 2008, however, it was clear there was a global glut in refining capacity and given the low margins and price controls refiners were loath to refurbish their plant or invest in new capacity when it was straightforward to import. Concern about importing fuel is also overblown when one considers that the oil required as an input is all imported. Worse, though. The government was considering a vanity project. PetroSA was asking for $11 billion to invest in a new refinery at Coega in the Eastern Cape. The new plant would effectively double South Africa s refining capacity. One of the interesting features of the government s plans to invest in this mega refinery, which will produce top quality fuel, is that it is likely to lead to the closure of one or more of the existing refineries, said David Wright, General Manager of Corporate Planning at Engen Petroleum, speaking at the time. The new Coega refinery will be more efficient in producing product from crude so it will produce about bbl/d product. By 2015 the SA demand will be in the 550 to bbl/d range, so we will only need to run the existing refineries at 50 to 67% of their capacity. The nature of refining profit is that the fixed costs are high so that high utilization is essential to make money, so one or more will close down. What is now called Project Mthombo was due to be ready for refining in South Africa cannot afford to postpone a positive decision on Mthombo lest we find ourselves in the terrible situation with regards to liquid fuels that we experienced in 2008 during the electricity crisis, wailed Nosizwe Nokwe-Macamo, CEO of PetroSA. In Current plans are that Project Mthombo will only be complete in Shades of Medupi. I issued five scenarios in my final report in September 2008; two 6

9 Special Report of which are now relevant: that fuel-price regulation remains in place, that low-sulphur fuel rules are effective from 2017, and that an offset incentive is agreed; with the second scenario being the same, but that PetroSA s Project Mthombo goes ahead as well. The R35 billion cost of 2008 has grown considerably. All the new refurbishment components are imported and the rand has weakened considerably. In 2013, when the government agreed to finance an offset covering refurbishment costs, it was R40 billion. A year later, and it is now R47 billion. It is no surprise that the existing refineries haven t rushed to invest. They have no idea when or even if Mthombo will go ahead. If it does, one or more of these refineries will close. Would you go through the process of shutdown, refurbishment, and re-engineering if you weren t sure if the plant had any future? Any delay in producing clean fuels will extend the period we don t have petrol here to support the latest vehicles, says Stuart Rayner, head of the fuels and emissions technical committee at NAAMSA. We re further behind than that. Europe is now implementing Euro VI in September Vehicles are already expensive in South Africa. Having to modify every new car to be able to use 20-year-old fuel specifications adds even more to the price. Sasolberg, the smallest of the country s refineries, has now been upgraded, coming on stream in November last year. The refurbishment was conducted by Fluor over a period of five months and cost about R11,7 billion. Only another three refineries to go, collectively responsible for about bbl/day of productive capacity. And there sits Mthombo. Not only will it double capacity, but it will also be entirely in the wrong place. The majority of consumers of petrol and diesel are in Gauteng. Our main distribution pipeline for liquid fuels runs from Durban to Johannesburg. That s a 555 km pipeline capable of carrying 26,7 billion litres of liquid fuels annually. It cost R23 billion and was completed only in Our two biggest refineries are based in Durban. Except Mthombo is to be built in Coega. That s 800 kilometres away in the Eastern Cape. The justification as always is jobs. About direct and indirect jobs are expected to be created during construction, and direct and indirect jobs when it s operational, claims PetroSA. Which is rubbish. Refineries may create jobs when they re being built but they need hardly anyone to run them. The entire existing refining manufacturing employment in South Africa is for people. And jobs will certainly be lost when other refineries close down to counter the new surplus. How serious is all this confusion? To the industry, it s pretty bad. The government has not issued any guidance as to whether the refiners will get all their investment back and, between this and Mthombo, are sitting on their hands. Vehicle manufacturers have no idea what they should be doing either. Lower quality fuels make for greater pollution. Poor air quality contributes to everything from asthma, to lung cancer, to the physical degradation of civil infrastructure, and looming climate change. They also cost more as South Africa s existing vehicles are old and inefficient using more fuel than more modern engines. We shouldn t end up with the sorts of liquid fuel shortages that would be equivalent to Eskom s incompetence. Neither will we need the equivalent of Eskom s virtual power generators where they randomly switch off small towns around South Africa in order to protect the cities (and the ANC s voters). Fuel can readily be imported. The refiners are happy to run their plants till they die and then simply switch to imported fuels. That way we d also get the very latest fuels produced in more modern refineries. The harm, though, is that South Africa is proving absolutely incapable of passing clear and decisive legislation which companies need to ensure clarity for their investment decisions. That uncertainty be it in mining, refining, or manufacturing is seeing investment go elsewhere. Far easier to build capacity in predictable economies and import manufacturers to South Africa. Six years later, let me revise my scenarios. Project Mthombo will continue to loom over refiners investment decision-making. None of the remaining refiners will be prepared to stick their necks out until PetroSA, and new investor Sinopec, produce a feasibility study defining whether Mthombo will go ahead. If Mthombo does go ahead and, très Medupi, it will be very late South Africa will import any fuel shortfall until it comes online. South African vehicles will continue to be inefficient and the benefits of new investment, fuel efficiency and reduced pollution will continue to hurt. Unfortunately, that sounds a lot like South Africa Inc, business as usual. z 7

10 Effects of biodiesel on plastics by David Grewell, Tong Wang, Melissa Montalbo-Lomboy, Linxing Yao, Iowa State University, and Ames, IA, Paul Gramann and Javier Cruz, The Madison Group, Madison, WI An understanding of the compatibility of biodiesel fuels on various plastics is essential to avoid unexpected failures and to help to ensure that this important resource does not gain a reputation for damaging plastic parts. Society of Plastics Engineers (SPE), USA. This article is based on a presentation given at the Society of Plastics Engineers (SPE) ANTEC 2013 and is republished here with kind permission. Abstract Many chemicals have the ability to attack plastics leading to failure. In some cases, the source of the chemical is not well defined. In this study, the effect of biodiesel, a fatty acid methyl ester, on various plastics, namely polyamide 6 (PA 6), polycarbonate (PC), acrylonitrile-butadienestyrene (ABS) and ABS/PC plastic blends was studied. Various feedstocks of biodiesel were also studied, including, soy bean oil (new and used), animal fat (tallow), corn oil as well as choice white grease. The plastics samples were tested following an ASTM standard where a predefined strain is applied to the samples prior to exposure to the solvent (biodiesel). This study has shown that biodiesel can be incompatible with engineering plastics, such as PC, ABS and ABS/PC blends. In the past decade there has been a continued rise of biofuel production in the United States due to the fluctuations of petroleum costs and negative impacts of fossil fuels to the environment. This has demanded the creation of a more sustainable energy resource such as bioethanol and biodiesel. The biodiesel industry, in particular, produced more than one billion gallons in 2011¹. The US National Biodiesel Board has noted that it is a key milestone for the industry. As of August 2012, about 699 million gallons biodiesel were produced, according to the US Energy Information Administration². Last year, there were 105 biodiesel plants in the US with an annual production capacity of 2,1 billion gallons. It is expected that these numbers will continue to increase as new feedstocks resources are explored. 8

11 Petrochemicals The use of vegetable oils in diesel engines was considered inadequate due to its high kinematic viscosity, which can lead to engine fuel deposits. Vegetable oils have to be reduced to a lower viscosity before they can be used as a diesel fuel. One of the methods used to obtain this is transesterification. In the presence of a catalyst (acid, base or enzyme), triglycerides in oils reacts with an alcohol (typically methanol is used), to produce biodiesel or fatty acid methyl esters (FAME) and glycerol. This involves three reversible stepwise chemical reactions that convert triglycerides to diglycerides to monoglycerides, then finally to glycerol. Each step releases one mole of FAME. The transesterification process decreases the viscosity significantly, correspondingly giving the biodiesel a viscosity that is low enough to be used in diesel engines. Standard #2 diesel fuel is a liquid diesel fuel derived from petroleum mainly composed of saturated hydrocarbons 9

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13 Brittle Failure failure Petrochemicals Triacylglyceride Methanol Ductile failure Stres Effect of chemical Brittle failure Glycerin FAME Time Figure 1: Transesterification reaction of triglyceride to biodiesel Figure 2: Effect of a chemical on the time to failure for a plastic and aromatic hydrocarbons. To be used as substitute for #2 diesel fuel, biodiesel needs to meet ASTM D6751 and EN14214 before it can be used as a substitute for standard #2 diesel. These standards give detailed requirements (eg, flash point, water and sediment content, other contaminant levels) that the fuel must meet. Biodiesel fuel is made from a reaction of triacylglycerides and methanol. The resulting biodiesel is essentially fatty acid methyl esters (FAME), as shown in Figure 1. It is known that many plastics will have incompatibility issues with ester-based chemicals³. This study investigated the compatibility of various plastics to six biodiesels formulated from different feedstocks. Chemical degradation Chemical degradation of plastic by a foreign material involves the reduction in length of the molecular chain and corresponding molecular weight of the polymer. It is generally observed that the longer the molecular chains of the plastic, the more desirable the mechanical properties, as well as other properties 4. This is primarily due to the entanglement of the long molecular chains. Chemical degradation involves a chemical reaction where the molecule is modified and effectively reduced in length. Environmental Stress Cracking Environmental stress cracking (ESC) involves stress and a foreign chemical synergistically working together to break molecular secondary bonds of the plastic 5. ESC is different from chemical degradation since it does not reduce the length of the molecules. The chemical penetrates the molecular structure with the assistance of stress and interferes with intermolecular forces allowing for molecular disentanglement to take place. Figure 2 shows a typical time to failure for a plastic. As the stress is reduced failure (cracking) takes longer to occur. ESC is an accelerated form of brittle plastic creep. It is associated with sustained stress over a period, involves molecular disentanglement and results in the plastic cracking in a brittle mode. The chemical associated with ESC accelerates the molecular disentanglement. In Figure 2, two transitions are shown: brittle-to-ductile and ductileto-brittle failure modes. The effect of a chemical that can cause ESC to occur is to shift this graph to the left, effectively reducing the time to failure at the same stress. Assessment of chemical compatibility Experimental data may be found on chemical resistance of some plastics to a number of biodiesels, however, very little will be found on ESC. To evaluate the ability of a plastic to perform while exposed to a foreign material, appropriate testing should be completed. It is important that the tests be run over a period of time to allow the fluid and application of stress/strain interact with the plastic. As stated above, ESC is essentially an accelerated form of plastic creep in a brittle mode. Following an ASTM standard 6, 7, 8, one can evaluate the compatibility of a plastic while subjected to stress. Test procedure To analyze several different plastic materials to various formulations of biodiesel, as well as, standard #2 diesel fuel, ASTM D 543 was used. The plastic samples were placed in a jig that applied a constant strain of 1,5% over a ten-day period, as shown in Figure 3 overleaf. Samples were also exposed to the standard diesel and biodiesels at zero applied strain. A strain of 1,5% is on the higher end of strains that are typically used for ESC testing. To ensure a constant exposure of the plastic to the chemical, 11

14 Table 1: FAME and fatty acid composition of biodiesel samples Sample Fatty Acid (FA), % Figure 3: A constant strain jig used for environmental stress cracking 16:0 18:0 18:1 18:3 18: FAME, % in sample, as received Total GC peak accounted by the 5 FAs, % Samples 3, 6, 7, 8, 9, 10 are as follows respectively, used cooking oil, soy, mixed feedstock, tallow, choice white grease, and distillers corn oil. Figure 4 Polycarbonate and Acrylonitrile-butadiene-styrene samples after exposure to biodiesel and 1,5% strain cotton gauze was wrapped around a two-inch section of the sample to which the chemical was applied. Testing was done at ambient conditions. The samples were observed on a daily basis and chemical reapplied as necessary. The samples were analyzed by visually observing cracking. Time for cracking to occur gave a comparative measure of the severity of the chemical. Plastic materials analyzed Four different plastic materials were tested. The samples were moulded under controlled conditions by Standard Plaque in Melvindale, Michigan, USA. Polyamide 6 (PA6) DSM Alkulon K222-D Natural Unreinforced Polycarbonate (PC) LG-Dow Calibre Clear Unreinforced Acrylonitrile-butadiene-styrene (ABS) BASF Terluran GP-22 Natural Unreinforced PC/ABS Sabic Cycoloy CX7240 white Unreinforced Biodiesel blends Ten biodiesel samples were obtained from Renewable Energy Group (REG) (Ames, Iowa). The samples were produced using the following feedstocks: used cooking oil, soy, tallow, distiller s corn oil, choice white grease (CWG), and mixed feedstocks. (NB: samples 1, 2, 4 and 5 were repeats of the other samples, but produced on a different date, thus they were not tested.) The biodiesel samples were analyzed using gas chromatography (GC). Table 1 shows the fatty acid (FA) and FAME composition of the samples. There were too many minor GC peaks to positively identify, thus only the five major peaks were presented. Additionally, tallow biodiesel has many other minor FAs or GC impurities outside the five major FAs, so the total GC peaks accounted by the five major FAs is low (mid 80%). It also has more unsaponifiable matter, which is reflected by the relatively low total FAME in the sample. Sample #3 Source: Used cooking oil Date: 8/17/2009 Sample #6 Source: Soy Date: 9/11/2012 Sample #7 Source: Mixed feedstock Date: 7/5/2012 Sample #8 Source: Tallow Date: 9/11/

15 Table 2: Effect of biodiesel fuels on plastic-cracking time Biodiesel Plastic PA 6 PC ABS PC/ABS #3 No cracking < 60 sec ~ 12 hours < 60 sec #6 No cracking < 60 sec ~ 12 hours 60 sec #7 No cracking < 60 sec ~ 12 hours 60 sec #8 No cracking < 60 sec ~ 12 hours 60 sec #9 No cracking < 60 sec ~ 12 hours 60 sec #10 No cracking < 60 sec ~ 12 hours 60 sec Standard Diesel No cracking Slight surface hazing No cracking Cracked inabout 5 hours Petrochemicals Sample #9 Source: Choice white grease (CWG) Date: 8/16/2009 Sample #10 Source: Distillers corn oil Date: 9/11/2012 Discussion The results of ESC testing are shown in Table 2. There are several general conclusions that can be made from the tests that were performed. It should be noted that the results are for the specific materials tested and should not specifically be applied to plastics of the same type. Molecular weight of the plastic is a driver on how well the plastic will perform when a subjected to a chemical and/ or stress. 1. The strained (1,5%) PA 6 did not crack when subjected to the biodiesel or standard diesel fuels. 2. The strained PC, ABS and PC/ABS were affected greatly by the biodiesel fuels. The PC and PC/ABS sample cracked nearly instantly when the biodiesel was applied to the strained samples (Figure 4). The fracture surface was indicative of environmental stress cracking with multiple crack initiation sites and crack progression in a brittle mode (Figures 5 and 6). 3. The strained ABS did not crack when subjected to the standard diesel fuel.

16 Petrochemicals Figure 5 Fracture surface of a polycarbonate sample after exposure to biodiesel and 1,5% strain Figure 6 Fracture surface of an Acrylonitrile-butadienestyrene sample after exposure to biodiesel and 1,5% strain Figure 7 Polycarbonate samples after exposure to standard #2 diesel and 1,5% strain 4. The strained PC was slightly affected by the standard diesel fuel with surface hazing taking place (Figure 7). 5. The strained PC/ABS cracked over a 5-hour period when subjected to standard diesel fuel. The samples were also subjected to each biodiesel with no stress applied (ie, pure chemical attack analysis) and to a constant 1,5% strain with no chemical applied (ie, creep analysis). In both of these conditions none of the samples cracked or showed any signs of microcracking or hazing. Conclusions The use of renewable fuels is on the rise. Biodiesel has a tremendous upside due to the number of sources where this fuel can be derived. An understanding of the compatibility of these fuels on plastics is essential to avoid unexpected failures. This will help ensure this important resource does not gain a reputation as damaging plastic parts. The chemical structure of biodiesel is nearly all fatty acid methyl esters, with which many plastics are not compatible. This study showed a number of strained plastics that failed when exposed to biodiesel. Some of these same plastics had little to no effect when exposed to standard #2 diesel fuel. z 2. U.S. Energy Information Administration, Monthly Biodiesel Production Report, Accessed November 3, 2012, from 3. Product Design Library, Chemical Resistance of Plastics and Elastomers, William Andrew Publishing (2002). 4. R. Nunes, J. Martin, J. Johnson, Influence of Molecular Weight and Molecular Weight Distribution on Mechanical Properties of Polymer, Polymer Engineering and Science, March (1982). 5. J. Jansen, Environmental Stress Cracking The Plastic Killer, Advanced Materials & Processes, June (2004). 6. ASTM D Standard Practices for Evaluating the Resistance of Plastics to Chemical Reagents. 7. ASTM D Standard Test Method for Environmental Stress- Cracking of Ethylene Plastics. 8. D.C. Wright, Environmental Stress Cracking of Plastics, Rapra (2001). References 1. National Biodiesel Board, Production Statistics, Accessed November 3, 2012, from 14

17 No electric car without plastic For several innovative components in the BMW i3, the electric vehicle from the BMW Group, the chemical company BASF, supplies versatile plastics and supported part development with extensive construction know-how. These include the backrests of the front seats, key reinforcement parts in the carbon fibre body, and the rear seat shell. By bringing together all our plastics expertise in the division Performance Materials, we can offer customized solutions to innovative customers such as the BMW Group and their suppliers worldwide as well as support them during component construction, says Raimar Jahn, Head of BASF s Performance Materials division. With the BMW i3, the BMW Group has taken a groundbreaking step into the future of the automotive industry, and BASF s intelligent solutions are making a key contribution here. The seat backrest in the driver s and passenger seats is the first injection moulded and uncoated structural component made from polyamide to have a visible surface and to be used in the vehicle interior. This lightweight hybrid component, weighing only 2 kg, embodies all the know-how of BASF s Global Seat Competence Team. The backrest, which integrates multiple functions, is made from a highly UV-stable polyamide 6 compound developed by BASF especially for such applications (Ultramid B3ZG8 UV). As well as providing sufficient rigidity, this material also ensures adequate elongation and toughness to meet the mechanical requirements of the BMW Group, and this within a temperature range of -30 C to +80 C. The seat backrest owes its final, complex and above all very slim shape to the early use of BASF s universal simulation tool Ultrasim. Thanks to the precise numerical simulation of the materials used for the backrest, release lever and belt guide, the calculated behaviour in the crash simulation matched the subsequent tests very accurately. Optimization could thus take place on the computer in the early stages, avoiding modifications later on in component development. The BASF simulation method Ultrasim effectively accompanied all the certificates required by law at different seat positions, temperatures and loads. Furthermore, the particular Ultramid grade is especially low-emission. It is very highly scratch resistance and its remarkable surface quality allow a visible use of the seat structure, which thus becomes an important element. Regarding the seat release lever, its material must not fail in a crash. Therefore, a special long glass fibre-reinforced Ultramid grade is employed in this application: Ultramid Structure B3WG8 LF. The BMW i3 s carbon body contains PBT (polybutylene terephthalate) structural parts between the inner and outer shell. The largest component and the first of its kind is a so-called integral component located in the BASF rear side area between the carbon fibre body shells. Apart from its load-bearing function in the event of a crash, it also serves to keep the two body shells apart and forms the rear opening for the side window. The self-supporting rear seat shell is made from BASF s Elastolit polyurethane system. For the first time in a serial production vehicle, carbon fibres are combined with a polyurethane matrix. The component integrates a variety of functions such as the cupholder attachment and storage tray, saving on both assembly work and weight. The PU structural foam Elastolit D is used as a reinforcing material in the whole roof frame, including the A-pillar. The highly pressure-resistant foam is manufactured to a carbon sandwich composite, thus supporting the structural rigidity of the vehicle. For more information on the products: and FOCUS ON PETROCHEMICALS Gas Week June 2014 The Liquefied Natural Gas (LNG) industry is at a crossroads. The emergence of the United States of America as a potential new supplier of LNG based on shale gas is transforming the industry. During the next few years a significant volume of LNG will come onto the market with changing business models increasing liquidity and providing opportunities for short term trading. Prospects for LNG importers have never been better with the development of Floating Storage Regasification Units (FSRU) enabling small scale localized imports. In addition, new pricing mechanisms are emerging creating arbitrage values between regional markets. It is essential for stakeholders in the local gas industry to understand current global trends and to be able to put the future of LNG in Africa in context. Keys to unlocking the potential of Liquefied Natural Gas is a workshop which will be facilitated by Malcolm Johnson, Director of emjay LNG Limited UK. Johnson is former Strategy and Planning Manager Natural Gas Business, Shell UK and Germany and Senior LNG Commercial Advisor with Shell International Gas. He will be in South Africa in June to facilitate an LNG workshop at the Institute for International Research s Gas Week. Delegates who participate at the workshop will get a thorough understanding of how LNG fits into the global energy scene and its potential to contribute to South Africa s energy needs. They will also gain insights into the opportunities and risks of developing LNG import and/or export facilities. This workshop has been tailored for senior managers and policy makers in the energy industry. It will also be beneficial for finance industry executives who are responsible for the development of energy projects. For more details, please contact Jacqueline Lües on tel: , jlues@iir.co.za or visit 15

18 Atlas Copco South Africa centralizes to new world-class facility Atlas Copco South Africa relocated to a new, purpose-built, multi-faceted facility, Atlas Copco House, in January The move centralizes this global industrial Group s business areas and divisions for the sustainable and streamlined delivery of end-to-end product and service solutions to south and Southern African mining and industry. The world class, state-of-the-art facility occupies a total land area of m² and is strategically located in Jet Park, east of Johannesburg, within close proximity to OR Tambo International Airport. South Africa was the Atlas Copco Group s first step onto the African continent in the mid Today the Group s extensive African footprint includes operations across the continent. As a specialist supplier of compressors, construction and mining equipment, power tools and assembly systems, the successful growth of Atlas Copco South Africa meant that we outgrew our old Witfield head office with some business areas based in other locations, explained Atlas Copco South Africa s Vice-President, Bernie Hanaray. The substantial investment made by our Sweden-based parent company into the establishment of Atlas Copco House shows strong commitment to and confidence in South African and cross-border business, mining and industry. The facility puts us together under one roof and will help build synergies between our four business areas - Mining and Rock Excavation Technique, Construction Technique, Compressor Technique and Industrial Tools - as well as Atlas Copco Business Services and Atlas Copco Holdings. The complex consists of a m² office administration building, a Distribution Centre (DC) which comprises a m² warehouse and m² workshop, a m² training facility (Academy) as well as a spacious yard area with ample parking. The facility meets the company s current needs with Ronnie Leten, Group President & CEO Atlas Copco AB, planting a tree to commemororate the official opening of the new SA facility sufficient flexibility to address any future expansion requirements. For further information please contact Kgothatso Masekela, Corporate Communications Manager on tel: or kgothatso.masekela@za.atlascopco.com.

19 PDO secures long-term gas supply with four Vorecons from Voith Petroleum Development Oman (PDO) has chosen the Vorecon hydrodynamic variable speed planetary gear from Voith for the expansion of its Saih Rawl Gas Processing Plant in Oman. A total of four Vorecons will control the speed of the turbo compressors that ensure gas production and processing in the Saih Rawl gas field. This gas field lent its name to the plant. The Vorecon delivers an impressive MTBF value of 48 years and a statistical reliability of 99,98 %. The natural gas coming from the gas field is transported via pipeline to the Saih Rawl Gas Processing Plant. This industrial complex in the Omani desert requires a specific pressure on the plant side in order to further process the gas. At the start of the gas production process, the natural pressure in the gas field is sufficient to operate the gas processing plant. As the mean time of operation increases, however, the pressure in the gas field in turn decreases and compressors then raise system pressure to the required level. PDO has selected the Vorecon variable speed planetary gear from Voith to provide flexible response to the varying gas pressure. Following commissioning in 2014, the Vorecons with a power of 20 MW will control the turbo compressors at a drive speed of up to rpm. The availability of the drive components is an important factor for ensuring the gas supply in Oman. The extremely high reliability of the Vorecon doesn t just reduce drive system downtimes, it also decreases associated costs. The compact Vorecon is much better suited to the extreme environmental conditions in the desert, such as heat and sand storms, if compared to other drive solutions. The quick and easy maintenance of the Vorecon represents another benefit for the operator. For more information contact Terry-Lynn McIntosh on terry.mcintosh@voith.com, or tel: FOCUS ON PETROCHEMICALS SkyNet celebrates ten years of exclusive partnerships SkyNet s success in the petrochemical sector comes without needing to compromise safety or BBBEE compliance. This year, courier and express parcel (CEP) specialist SkyNet celebrates ten years of exclusive partnerships in the petrochemical sector, managing logistics for clients including Sasol, Engen, Total, Petro SA and Shell. We have second-perimeter access to some plants, says Eugene Swanepoel, GM, SkyNet. To be allowed further into the facility than the first perimeter, we obviously have to meet stringent health and safety standards. We maintain the highest SHEQ compliance, as well as ISO and SABS accreditation. SkyNet s Sales and Marketing Manager: Africa, Diederick Stopforth, says the size of its footprint (and the efficiency this enables) is also a key to its growth in petrochemicals. There s no question that safety is vitally important, he says, It s a non-negotiable in this industry or any industry moving hazardous substances. But once your accreditations and SHEQ standards are in place, coverage and efficiency becomes just as important. We re currently running 74 distribution hubs (50 in SA and another 24 around the SADC) and delivering to over 400 towns across the country daily. In fact, we opened new branches in Secunda and Three Rivers specifically to service our Sasol contract. You have to have a big footprint to be able to deliver everywhere: whether it s to head office, the refinery, or a petrol station out in the sticks. SkyNet s 98% on-time, in-full delivery record is not just a matter of reputation. Even the slightest glitch can result in serious losses. Shutting down a plant for maintenance needs to be meticulously planned and precisely executed. Every minute you re off-line you re literally losing money, notes Swanepoel. In that situation, when a client opens up a machine to find they have to replace a part and don t have stock, they need a courier that delivers fast. And if they hit an unforeseen snag out of their control-communication becomes king in sorting the situation out. During an unplanned plant stoppage if something breaks down that speed and reliability is even more important. As South African companies continue expanding north to service African industrial growth, express-courier reliability will remain crucial. Heavy industries are not the only ones benefiting from these partnerships. Post-recession, many retailers save costs by keeping less stock on shelf, relying on just-in-time delivery that matches demand a perfect fit for any CEP with an impressive footprint and reliable, visible, reactive supply chains. Our owner-driver initiative, already four years old, does exactly what the BBBEE codes announced last year intend, with respect to employment equity at management level, said Stopforth. SkyNet is 45% black-owned and our BBBEE rating is now at level 3. Stopforth credits SkyNet s expanding relationship with SA s major petrochemical firms to its focus on the industry s core needs: safety, reliability and transformation. Success in the CEP market, it seems, takes all three. For more information contact Kibi Magome on tel: z 17

20 Why you should choose your valves carefully A comparison of available solenoid valves By Philipp Wahl, Marketing Concepts, Festo AG & Co KG This article contains an introduction to valve technologies, what you need to know about poppet valves, piston spool valves and the cartridge principle, and how to decide which valve type suits your requirements best. The increasing demands placed on valve technology in recent years have led to a formidable extension of the range of available technologies and valve types, models, and properties. The most commonly used are poppet valves and piston spool valves. Nowadays, there is therefore a much wider choice of customized valve technology available to plan a project successfully. However, choosing the right parts for the application at hand requires comprehensive knowledge and an accurate appraisal by the consulting engineer or technician. Valve technologies Poppet valves and piston spool valves are the most commonly used valves for controlling compressed air. Flat slide valves, rotary slide valves, piezo valves and other technologies tend not to be used as often. The chart in Figure 1 offers an example of how the two common technologies can be subdivided. Among the piston spool valves, the valves with a cartridge seal are particularly interesting. This type of valve has lower leakage values and offers significantly higher operating pressures. What you need to know The poppet valve The very simple construction and the option of using any material often makes the poppet valves more inexpensive than the piston spool valves. For instance, a 5/2 poppet valve (see Figure 2 on page 21) only requires three axial seals, but there are more advantages with this technology: The actuation strokes are small, which allows for shorter switching times. The axial sealing technology is resistant to soiling. Poppet valves do not require lubrication, which is an advantage in terms of chemical compatibility with lubricated compressed air. The greatest drawback with poppet valves is the relationship between space and flow, due to constructional constraints. Poppet valves always offer a lower flow than slide valves, the constructional width being equal when it comes to pressure-independent models. The reason for this is the greater structural demand; in pressure-dependent valves, the control pressure is dependent on the operating pressure. This is because when the air flows through the valve (as seen in Figure 2) from channel 1 to channel 2, the surface area D2 is larger than D1. Since the same operating pressure is exerted on both surfaces, an imbalance of forces occurs, which has to be compensated. Furthermore, it needs to be noted that this valve construction is not always without overlap. Depending on the design, a change of switching positions can lead to overflowing between the channels. This gives rise to unnecessary leakage and noise. 18

21 Pumps, Actuators & Valves A compressed air consumption analysis can determine the precise compressed air consumption of an installation. Photo: Festo Figure 1: Examples of valve technologies The piston spool valve Whereas the actuation forces in poppet valves are relatively great, they are much smaller in piston spool valves, because the valves do not have to be switched against any forces generated by the operating pressure. The problem with overlap is also easily solved, as can be seen in Figure 3 on page 21. However, there are drawbacks with this valve type too. For example, the strokes for switching operating positions are longer than with poppet valves. These longer strokes and the placement of several pistons mean that the piston 19

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23 Pumps, Actuators & Valves Figure 2: Pressure-dependent poppet valve Figure 3: Piston spool valve Figure 4: Hard-sealing system Figure 5: Soft-sealing system with gasket on the piston Figure 6: Soft-sealing system with seal in the housing Figure 7: Increased seal wear due to the Bernoulli effect at a pressure of approx. 8 bar or higher 1. The high pressure and the restriction of the channel produce a higher air flow rate through the valve 2. The pressure in the valve is reduced due to the increasing air flow rate 3. The greater static pressure on the groove base forces the seal slightly upwards 4. When switching positions, the valve is squeezed harder and is potentially worn faster spool valves on the whole have to be longer. In terms of manufacturing, the piston spool valves are also more challenging, particularly when it comes to sealing technology. Two categories have evolved in this area: Category 1: Hard-sealing systems These sealing systems are more durable, but also more demanding. The durability is a result of the absence of soft rubber sealing elements in the piston spool valve. This means that valves using this sealing technology are immediately ready for full dynamic use even after longer periods of inactivity. In soft-sealing systems, there may be adhesive effects, which cause the sealing elements to wear out faster. The greatest challenge with the system is that the air gap surrounding the moving piston must not be larger than a few micrometres. A metal sleeve is often used, in which the valve spool moves. The sleeve then works both as a seal and as a guide for the valve spool. It is crucial that the sleeve and Figure 8: Piston spool valve with cartridge principle Moulded elastomer seal Metal housing Figure 9: Cartridge seal the spool are made with the same material, since different materials have different thermal expansion coefficients. If this is not taken into consideration, greater leakage will occur, and jamming of the spool may also occur. The combination of the sleeve and the spool therefore has to comply with many technical specifications, since even the smallest deformation in the housing, eg, due to tightening of screws, can damage sleeves and affect the life and leakage values of the valve (see Figure 4). In conclusion, hard-sealing systems are very robust and durable. The greatest drawback is that there is always a certain leakage with these systems because of the air gap. Furthermore, their flow capacity is lower than that of other valves with the same constructional dimensions. Category 2: Soft-sealing systems A technical alternative to hard-sealing systems is to use rubber gaskets (O-rings or moulded elastomer seals) on the piston (see Figure 5). 21

24 Pumps, Actuators & Valves Which valve type suits you best? A valve selection aid Both valve types; piston spool valves and poppet valves, come with their advantages and disadvantages. However, if you are looking for a type of valve with low leakage values and the option of dual-pressure operation 1 with vacuum and ejector pulse, or if you require high operating pressures, the most suitable is probably a piston spool valve with cartridge sealing technology. Table 1: Valve selection aid Relationship between valve size and flow High operating pressures up to 16 bar Vacuum operation Piston spool valve (seal on piston) Piston spool valve with cartridge principle Not available / Reverse operation Not available Resistance to polluted air Low leakage values Switching time Lubricant compatibility Conventional poppet valve (pressure-dependent) +++ = Excellent ++ = Good += Satisfactory 1) Pressure-compensated poppet valves may also be used for dual-pressure operation. 2) Depending on the structural design 3) If lubricants are used when working with compressed air, this will hardly affect the poppet valves, as their operation is usually dry However, in piston spool valves, chemical processes involving the lubricant may occur in the valve The Festo Technology Centre in Esslingen near Stuttgart. Festo About the author Philipp Wahl studied Mechanical Engineering, specializing in production technology at Reutlingen University in Germany and completed his MBA in International Marketing Management at ESB Reutlingen. Whilst working at Trumpf Inc (USA) he completed his thesis which was subsequently patented by Trumpf Inc. He gained experience as a design engineer in automation systems for a number of industries during his time as a project manager for Manz AG, before joining Festo AG & Co KG as part of the strategic marketing team. For more information pwhl@de.festo.com or tracey.swart@za.festo.com. The problem with this alternative is that the rubber gaskets may be worn down quickly when in contact with the channel edge the so-called control edge. The control edge must therefore be carefully designed, as only optimal planning of the control edge, the moulded elastomer seal and the piston guide can guarantee a soft passage with a minimum degree of wear. There is, however, yet another alternative. As illustrated in Figure 6 on page 21, the seals can be mounted directly in the valve housing. This looks like a great option, but there are two disadvantages. Firstly, the recesses required are difficult to produce and, secondly, the Bernoulli effect will cause the seal to be pulled out at a pressure of approximately 8 bar or higher. This again causes greater wear on the seal. Figure 7 shows the process in detail (see page 21). The cartridge principle for piston spool valves One solution to the problem described in Figure 7 is to use moulded seals in metal cages. The seals are thus retained in recesses in the metal housing; the so-called cartridge principle (Figures 8 and 9 on page 21). The advantage of this solution is that the valve will not be pulled out of its position even at an operating pressure of up to 16 bar, thanks to the recesses in the metal cage. This ensures a significantly longer valve life. In addition, the quality of the sealing between the piston and the elastomer seal is good enough for the cartridge principle valves to be used for vacuum operations without any problems. z 22

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26 KSB and coal-fired, solar and nuclear power plants According to a recent release, KSB s LUV pump is the power industry s best-performing glandless boiler recirculation pump. Power producers are said to recognize the LUV as the gold standard in high-pressure, high-temperature pumps. Traditionally an integral part of the boiler systems in coalfired power plants, the LUV has become the pump of choice for solar and nuclear plants as well. KSB is continually testing and challenging the design of the pump to ensure its adaptability for evolving markets, such as Concentrated Solar Power (CSP), which requires continuous cycling. Through Finite Element Analysis (FEA), temperature and pressure effects on material and internal clearances are efficiently maintained providing a reliable design. LUV pumps feature a single-shaft design and a unique wet squirrel-cage motor that creates a completely leak-proof product. Forged, not cast, the LUV is excellent for hightemperature and high-pressure conditions. LUV pumps lifespan matches that of the plant. When maintenance is required, The LUV is optimized to manage the most severe temperature and pressure transients of today's boilers KSB will provide service through specially factory-trained and employed technicians who know the pumps thoroughly. For more information contact Jochen Kastner on tel: or jochen.kastner@ksb.com S.A.M. Engineering serves the chemical industry with quality and innovation S.A.M. Engineering is a manufacturer of quality centrifugal pumps with over 25 years experience in the industry. Since 1986, they have supplied in excess of pumps to the oil, gas and petrochemical industry due to their pumps being designed to offer a wide range of solutions built to customer specifications. S.A.M. Engineering believes in quality above all else, demonstrated by their implementation of the ISO 9001:2008 Quality Management System. With a local manufacturing facility based in Boksburg and an in-depth knowledge of industry requirements, S.A.M. Engineering is able to custom build pumps for all purposes. With prominent clients such as Sasol, Cactus Carbon, Foster Wheeler and Euchem, S.A.M. Engineering has proven its ability to take on significant projects where quality and the ability to handle volatile and highly flammable liquids typically found in the chemical industries is a must. The chemical processing industry is characterized by the transfer of highly corrosive, high temperature chemicals, requiring only the most advanced material technology to satisfy stringent safety demands. S.A.M. Engineering s pumps for the chemical industry are designed to provide ultimate performance capabilities, namely custom steam jacketing and special seal arrangements for high temperature applications. Add to this bigger shafts and bearings as well as low slenderness ratios, and it is clear that S.A.M. Engineering offers a superior robust pump. S.A.M. Engineering offers a professional service, top quality products and solutions with the shortest lead times. For more information call or pumps@sameng.co.za 24

27 AZ-ARMATUREN: Locally manufactured valves make a come back The South African valve manufacturing and foundry industry has declined substantially during the past years due to the flood of imported products. To turn the industry around, in March 2014, the National Treasury released an instruction note which invited all State Owned Companies to buy locally manufactured valves with a minimum local content of 70%. The obvious benefits of this were the creation of many new jobs throughout the value chain, increasing economies-of-scale to improve global competitiveness and providing the impetus to rise again for a production sector that was once on the edge of dissolution. The instruction note is available on AZ-ARMATUREN South Africa, since its establishment in 1985, has always been committed to manufacturing valves in South Africa for the sub-saharan African market. Furthermore, the company purchases most of the castings and raw materials from South African manufacturers and foundries. This leads to short delivery times, high flexibility, job creation and skills development. The AZ-ARMATUREN group is a German owned, worldwide acting manufacturer of high quality valves. The company also has production plants in Germany, Brazil and China. AZ-ARMATUREN South Africa is a member of the Valve and Actuator Manufacturers Cluster of South Africa (VAMCOSA). One of the main goals of VAMCOSA is to grow the South African valve and actuator industry and encourage localization, which will, in turn, improve job creation and skills development. Nowadays, AZ-ARMATUREN South Africa is the sole South African manufacturer of plug valves and allied products. The product range includes the following valves: Plug, fully lined, sampling, actuated and special. Furthermore, the company provides after sales service (repairs, stock, and breakdown-service) and can assist in technical solutions. For more information tel: or info@az-armaturen.co.za. FOCUS ON PUMPS, ACTUATORS & VALVES

28 FOCUS ON PUMPS, ACTUATORS & VALVES BMG FluidPower extends range of open frame pinch valves BMG s Fluid Power division has extended its range of FPV valves to now include new open frame pinch valves, designed for enhanced operating efficiency and extended service life in diverse sectors. These valves, which were launched in August 2013, are particularly well suited for the control and isolation of abrasive slurries. These new open frame pinch valves, which have been developed on the successful design of OMSA s patented FPV diaphragm valves, can also be fitted with replaceable polyurethane-lined rubber sleeves as an option, which replace conventional rubber sleeves. This sleeve design increases the life span of the valve due to the high abrasion resistance of the polyurethane lining, said Wayne Holton, BMG s Fluid Power Division. Pinch valves with a design where the sleeve is pinched to close mechanically or automatically by fluid pressure in the body are ideal for controlling the flow of liquids, powders, solids and abrasives. These pinch valves are available with a short and long frame design, in sizes between DN50 and DN500, with special face-to-face dimensions and larger sizes BMG s Fluid Power division has extended its range of FPV valves to include new open frame pinch valves, designed for enhanced operating efficiency and extended service life in diverse sectors. These valves are particularly well suited for the control and isolation of abrasive slurries. on request. The body is made from cast steel, but stainless steel is also available for specific applications. These valves have manual, pneumatic and hydraulic actuation. FPV diaphragm and pinch valves, which are 100% locally manufactured, are available in many different materials, with various pressure ratings to meet exact requirements. BMG s extensive range of quality branded valves includes resilient seated gate valves, butterfly valves and ball type check valves. Also in the range are knife gate valves, thermoplastic valves and angle seat valves. Key to BMG s portfolio are FPV diaphragm, wedge gate and pinch valves. For further information contact Veronique van Niekerk on tel: , or veroniquev@bmgworld.net.

29 Water/wastewater energy efforts boost smart pumps Story by Aaron Hand, Water and wastewater plants typically are some of the largest consumers of energy, accounting for percent of the energy used in a municipal government, according to the US Environmental Protection Agency (EPA). Looking at the situation in Europe, Frost & Sullivan has found that environmental regulations and increased focus on optimizing energy consumption in the water and wastewater industry is boosting the adoption of smart pumps across Europe. Minimizing pump lifecycle costs is another factor in new adoptions. Although smart pumps have a higher initial cost than standard pumps, they reduce total cost of ownership by lowering maintenance and operation costs. Greater process automation along with the increase in efficiency and quality are expected to be important pump selection factors in the European water and wastewater industry. Tight environmental regulations designed to reduce greenhouse gas and carbon emissions lend significant support to the smart pumps market, said Niranjan Paul, industrial automation and process control research analyst for Frost & Sullivan. This includes the Euro 2020 directive, which targets a 20 percent reduction in greenhouse gas emissions from the levels experienced in 1990, and the Ecodesign directive that sets rigorous ecological requirements for energy-related products sold across Europe. However, maintenance personnel in water and wastewater treatment facilities, particularly in the municipal sector, are reluctant to install smart pumps, concerned that they would add to the complexity of installation, operation and maintenance, thus increasing the risk of stoppages in water supply. Even end users, who are aware of the benefits provided by smart pumps in terms of energy efficiency and lifecycle costs, demand stringent tests for quality and reliability before installation, the study found. Moving into the water quality monitoring equipment will help pump manufacturers expand their customer base and combat the intense pressure on profit margins realized by manufacturing and selling only commodities such as pumps and valves, Paul said. The smart water grid market will gradually become more populated as the focus on integrating pumps with various control systems, such as supervisory control and data acquisition, increases. New branch manager appointment at Valve & Automation Valve & Automation (V&A) is pleased to announce the appointment of Roy Taljaard to the position of Branch Manager for the Johannesburg branch of the company. Roy joined V&A in 2007 where his extensive instrumentation experience enabled him to take leadership on intelligent positioners and ESD devices. He was later appointed product specialist for the V&A icon positioners, and then, sales manager for the Johannesburg branch. In January 2014 Roy was appointed Branch Manager. To contact Roy, call or roy.taljaard@valve.co.za. OMSA supplies filters to Bloemfontein The need for water supplies to be efficiently managed and operated has never been as important as it currently is when one looks at the amount of contaminated water reports being lodged with municipalities or water management suppliers. New feed water supply pump systems have recently been installed in Bloemfontein s local water supplier s facilities and have Mahle water filtration systems, from OMSA, included in the water quality processes. The Mahle water filters are automated, used to prime and lubricate the water feed pumps, with a backflush self cleaning mechanism which ensures that the water that is supplied is clean water and eradicates the risk of contamination, which may damage the water pump mechanicals. For more information contact Xen Papastamopoulos, on tel: , or xen@omsa.co.za. 27

30 FOCUS ON PUMPS, ACTUATORS & VALVES Hot water cascade system for sterilization of liquids The hot water cascade system developed by MMM Münchener Medizin Mechanik GmbH enables liquids in closed receptacles made of glass or other temperatureresistant materials (such as ampoules) to be sterilized quickly, reliably and gently. This plays a major role in pharmaceutical/ biotechnology production. GEMÜ valves are used to regulate the filling of the sterilization chamber during the process. This is first filled up to a defined level with deionized sterilization water. This water then circulates through a steamheated heat exchanger and cascades over the item being sterilized at a continuously rising temperature of up to 121 C. In the subsequent cooling phase, the sterilization water flows through the now water-cooled heat exchanger and cools the item being sterilized down to a specific temperature. GEMÜ 554 angle seat globe valve and GEMÜ 490 butterfly valve in equipment room Pneumatically actuated GEMÜ 554 globe valves control the filling of the sterilization chamber with water and the way in which the heat exchanger is heated by steam and cooled using water. By contrast, GEMÜ 490 butterfly valves are used in the circulation line, as these have significantly more compact installation dimensions yet very high flow rates in comparison with pneumatically operated angle seat globe valves of the same nominal diameter. Furthermore, to meet these stringent requirements, they are fitted with highly resistant TFM TM plastic and FDA-approved silicone as a sealing material. Background information GEMÜ is one of the world s leading manufacturers of valves, measurement and control systems. Over the course of 50 years, this globally focused, independent family owned enterprise has established itself in important industrial sectors thanks to its innovative products and customized solutions for process media control. GEMÜ is a world market leader for sterile valve applications in the pharmaceutical industry and biotechnology industries. Today, the GEMÜ Group employs over 800 employees in Germany and more than 1400 worldwide. Manufacturing is carried out at six manufacturing sites in Germany, Switzerland, China, Brazil, France and the USA. From Germany the Group coordinates global marketing with 24 subsidiaries and with a large distributor network in 53 markets, the GEMÜ Group is active on all five continents. GEMÜ will continue to establish itself in future markets with its international growth strategy. To achieve this, GEMÜ opened a new Production and Logistics Centre in A broad based modular system and adapted automation components mean that predefined standard products and customized solutions can be combined to make over product versions. Further information can be found at z

31 SAIChE ICCT/SAIChE Conference July 1 August AIChE President, Otis Shelton ICCT is the most renowned conference on chemical thermodynamics and is hosted by IACT every two years. The International Association of Chemical Thermodynamics (IACT) and the South African Institution of Chemical Engineers (SAIChE) will be jointly hosting the International Conference on Chemical Thermodynamics (ICCT) and the SAIChE National Conference from 27 July 2014 to 1 August 2014 at the Durban International Convention Centre in Durban, South Africa. The short name of this joint conference is ICCT/SAIChE 2014 and the website address is icctsaiche2014.co.za/ South Africa, as is the case with our continent and indeed the rest of the world, is challenged to develop its society through a future of constrained resources. Sustainability is a core requirement in our thinking as we grow our technologies to carry forward human capital development. As research scientists and chemical engineers our professions must lead in making bigger strides and pushing the boundaries in human capital development. Prof Peter Atkins, Lincoln College, University of Oxford, Oxford, England Prof Peter Atkins, Lincoln College, University of Oxford, is another speaker at the ICCT/SAICHE Conference. Peter Atkins taught chemistry at the University of Oxford from 1965 until his retirement KwaZulu-Natal Branch 4-6 August 2014 The South African Institution of Chemical Engineers KwaZulu-Natal Branch will be hosting the Kister Practical Distillation Technology course that will offer 3 CPD credits. It will be held at the Birchwood Hotel, Gauteng from the 4-6 August. Cost per person: R excluding accommodation; included in the cost are: The place to discuss these challenges and related chemical thermodynamic and chemical engineering developments is at ICCT/ SAIChE 2014! The featured speaker is Otis Sheldon, President of the AIChE Board of Directors, New Fairfield, CT, United States. Otis Shelton received his BS and MS degrees in chemical engineering from the University of Houston. In 1967, he joined Union Carbide Corporation in Texas City, Texas where he held various manufacturing assignments in low density polyethylene production, suspension/non-solvent vinyl chloride production and operations supervision of the Texas City Marine Terminal. Later, he worked in corporate human relations recruiting engineers for Union Carbide s US operations. In 1986, he helped lead the development and implementation of a corporate Health, Safety & Environmental Audit program which provided in-depth assessments of Union Carbide s worldwide manufacturing facilities. In 1992, Mr. Shelton joined Praxair where he lead its Safety and Environmental Assessment Program which conducted thorough assessments of health, safety, process safety, distribution, environmental and emergency planning programs at Praxair facilities worldwide. Now retired, he began his tenure as AIChE President beginning on January 1, in His interests were in theoretical chemistry. In the course of his career he switched largely to writing textbooks and books on science for the general public. They now number about 70 and include his Physical Chemistry (about to appear in its 10th edition) and Chemical Principles (currently in its 6th edition). He continues to write and lecture worldwide, and is particularly interested in the challenges of teaching thermodynamics to students and sharing its insights with the general public. 1) A copy of Kister s book: Distillation Operation, McGraw-Hill, 1990; 2) A copy of Kister s book: Distillation Trouble shooting, Wiley, 2006; and 3) A manual containing information addressed during the course, which is not available in the books. More information is available on the SAIChE website. z SAIChE COUNCIL MEMBERS President Imm. Past President Honorary Treasurer Honorary Secretary Vice President Vice President EXCO Member EXCO Member Council member Council member Council member Council member Council member Council member Council member Chair Gauteng Chair KZN SAICHE NEWS RH Grob AB Hlatshwayo L van Dyk CM Sheridan SE Iyuke D van Vuuren JJ Scholtz Z Harber KG Harding EM Obwaka BK Ferreira M Low L Greyvenstein D Ramjugernath JG Potgieter Dawie van Vuuren S Mazibuko SAIChE contact details PO Box 2125, NORTH RIDING, 2162 tel: ; fax: (0) ; saiche@mweb.co.za; website: 29

32 Management of change A tool for systematically managing the safety effects of change by Rod Prior, MD, SHExcellence, Johannesburg, South Africa Unmanaged change can and has posed risks to hazardous processes. Many accidents, in many countries including South Africa, have occurred because of uncontrolled changes to processes, equipment, administrative systems, control systems and aspects of people and organizations. A formal system is required to manage change and/or modifications. Process Safety Management (PSM) is an important process or system which is aimed at preventing losses of containment of hazardous materials leading to fires, explosions and toxic releases. These releases can harm people, damage the environment and result in major financial loss through asset damage and loss of production. One of the key elements of a PSM system is Management of Change (MOC). MOC attracted the interest of the process industries in A cyclohexane vapour gas explosion (50 tons) at a plant in Flixborough, England claimed 28 lives. The incident arose from the use of a temporary bypass between two reactors (see diagram opposite). The missing reactor (No 5) was under repair and the plant wished to continue producing. A bypass was constructed of a dog s leg pipe and expansion bellows at each end. After two weeks operation at 10 bar and 150 C, the modification failed with the bellows rupturing and releasing hydrocarbons above its boiling point. The modification had not been subject to any form of risk identification/assessment and no drawings were made of the bypass. There was no competent mechanical engineer on site. The incident resulted in changes to UK legislation and an appreciation of the risks posed by unmanaged change. Change is, of course, required for business improvement whether it is for reduced costs, improved quality or a higher level of safety. Change is seen as a positive activity but has to be managed to ensure that the risk profile of the equipment/plant/operation is increased. Our thinking is often simplistic. We have a problem. We think of a solution and then are so pleased we have solved the problem that we do not see the unwanted side-effects. Many accidents have resulted from uncontrolled change. Some have taken place in South Africa. What kind of change? Changes which may result in major process incidents can take many forms. The changes fall into four classes: Hardware (plant, equipment), process changes (temperature, catalyst); Systems (procedures, instructions), Control systems (instrumentation); People (individuals, jobs, organizations). In addition, change may not be instantaneous but may occur over time. Change may not be deliberately introduced but happen indirectly or by accident. Hardware changes are generally obvious and these changes are recognized by most organizations. Examples include: Materials of construction Addition or removal of items in a plant Change in equipment size, eg, bigger pumps Isolation of part of plant Changes to structure 30

33 Plant Maintenance & Risk Analysis Changes to means of support. Process changes include any changes to the process variables (temperature, pressure, ph, etc), which are outside the permitted operating range. Some changes are: Operating outside envelope (Chernobyl) Temperatures and other process variables Catalyst Quantities/ratios of reactants Steps in batch process Raw material or additives Change in concentration Supplier specification. The difficulty is in knowing what changes are significant. The chemistry and process dynamics are often not known well enough to be clear about what size of change will make a significant difference. In some industries any change may be catastrophic. Administrative or systems changes may include the following: Change of procedures, eg, emergency procedures Introduction of new method New or changes training Control system changes may include the following: New control system Automation of manual tasks Hardware component changes Diagram of temporary by-pass between two reactors Power supply Addition or removal of trip system Change of test frequency of trip/alarms Networking. Change in authority level in who can change instrument settings. The area can be technically complex and is often left to the instrument technicians or external contractors. There is therefore a danger that these changes will either not be recognized or there will not be a capability to evaluate or accept the changes. 31

34 A simple example would be to reduce the trip testing frequency for cost reasons. The reliability of the trip could be reduced. The trip may not then work with the reliability as determined in the original design. People changes can be complex, indirect and very difficult to evaluate. Changes could include: Delayering, eg, remove supervisory level Acquisitions Change of organization structure Centralization/decentralization Key SHE personnel moved/removed Reporting relationships Downsizing/use of contractors Overloading operators Using untrained/incompetent people Automation. A lot of judgement has to be applied in this area. An example might be the removal of the supervisor level for cost reasons. One role of the supervisor (the classic old-fashioned role) could be to oversee the start-up of a plant which was being done by operators. The supervisor, normally through his experience, can detect operator mistakes and guide them through unusual process deviations. This role of the supervisor is that of an independent layer of protection. Without this, the risk of a hazard materializing could be significantly increased. Legislation In the USA one of the 14 elements in the 1992 OSHA PSM Regulations covers MOC. Some of the main requirements are: A written procedure for MOC Procedure to cover changes to chemicals, technology, equipment, procedures Procedure must cover justification, impact on safety and health, authority, training, update documents. In the EU this is covered by the SEVESO 11 DIRECTIVE GUIDELINES but is not mandatory. A requirement is that the Safety Management System (SMS) must include MOC and that all forms of change must be covered. In the UK MOC is covered in the detail of the COMAH Regulations. There is a clear definition of all the kinds of change to be considered including the people aspects. In South Africa there is no specific legislation covering Management of Change. In the MHI Regulations reference is made to redoing the Risk Assessment if it is suspected that it no longer relevant. The Explosives Regulations call for physical changes to be motivated to the Department of Labour. A risk assessment method to help determine whether existing controls are adequate or whether new controls or safeguards are needed Definition of who should be involved in the risk assessment Definition of who shall authorize the change The requirements to action and close out the change (documentation). Expected outcomes of a MOC system A well-designed and used MOC system will provide the following outcomes for an organization: A structured approach to change issues Tight control over all types of change No significant increase in risk profile Records of all aspects of the modification Proof of close-out of all required actions Information on which to base an audit Up-to-date documentation such as training and operating instructions Confidence in the performance of a modified plant. Pitfalls in a MOC system The like for like or replacement in kind carries potential risk if it is used as a bypass around the formal change management system. Nothing is ever identical in every aspect and specifications do not cover every aspect. The item or material supplied to the same specification by different suppliers has lead to problems. Certain industries such as pharmaceuticals and explosives cannot accept any form of uncontrolled change. Creeping change is very difficult to manage. As the change is gradual it is difficult to detect. A specific period of change may not result in an obviously dangerous situation. An example is where steam consumption at a plant has gradually fallen. Flows through the mains became too low to prevent condensate accumulating. On one of the mains, an inaccessible steam trap had been isolated and on the other the main had settled slightly. Neither of these mattered when the stem flow was large, but it gradually fell. Condensate accumulated and finally water hammer fractured the mains. During a recent investigation into a local oil refinery naphtha leak, fire and explosion, it was established that corrosion by organic acids was an ongoing issue. NDT testing Basics of a good MOC system A formal change system is needed to manage the many forms of change that might apply to hazardous processes. The system needs: Definition of the change types it is covering How to recognize the change types Who should motivate changes for consideration An evaluation method to decide whether a change is acceptable. The change should not increase the risk profile of the operation 32

35 Plant Maintenance & Risk Analysis was carried out to monitor the rate of metal loss. However the spot testing method for thickness missed a few square centimetres on a T junction where severe local corrosion took place. See photograph on the left illustrating the failure. Managing people change is perhaps the most difficult area to control. This is a new type of change for South Africa but not for the UK. People, job and organization changes are very diverse. The effects are often indirect. Changes are often induced without any consideration of impact on process safety. Minor changes The impact of physical changes can be subtle. In the first example (see rough diagram above), the position of the relief valve for the pressure vessel was moved from the inlet pipe to a dead end on a pipe on the vessel with the inlet moved to another point. You may argue that the whole system will be at the same pressure BUT the dead leg was not kept clear by the flow and clogged up. The relief valve was effectively isolated. In the second case the relief valve was sized to take the full inlet flow with all exit lines closed. An extra inlet line was added. If both lines are used together then the relief valve would be too small to relieve the total flow and the vessel might burst under extreme conditions. Both cases make the point that even small changes need to be subjected to a formal evaluation process. Temporary change A temporary change may expose the operation to exactly the same hazard as a permanent change. The only difference is the length of time for which the operation is exposed to the potential of the hazard materializing. So it boils down to the question that Clint Eastwood asked in his role of "Dirty Harry": "do you feel lucky?" Flixborough was a temporary modification! The same process should be used for all changes whether they are temporary or permanent. Bypassing of trips The trip (or Safety Instrumented System) is often the final automatic barrier that prevents the major fire, explosion or toxic release event. This has been the cause of many serious incidents. In some cases there has been a history of bypassing trips often because spurious trip failures had been experienced. This clearly is evidence of a poor safety culture. It is not appreciated how significant a bypass is. Bridging a trip changes the risk profile of an operation significantly. Should the trip be SIL rated at 2 (quite common), then the risk will be increased by a hundredfold with the trip being isolated. Sometimes trips must be bypassed for a start-up. This should be done only with the greatest care and a replacement barrier such as a supervisor, needs to be introduced to make up partially for the loss of trip protection. Conclusions Unmanaged change can and has posed risks to hazardous processes. Many accidents have occurred because of changes to processes, equipment, administrative systems, control systems and aspects of people and/or organizations. A formal system is required to manage change/modifications (MOC). This system must cover the nature of the proposed change, an evaluation of the change in risk because of the change, an evaluation of the suitability of existing controls and the proposal of new controls if needed. A suitable multi-disciplinary team is required to evaluate the change and the change has to be authorized at a suitable level. The required actions to close out the change must include the updating of all the documentation. z 33

36 FOCUS ON PLANT MAINTENANCE & RISK ANALYSIS 14th annual African Utility Week and Clean Power Africa More than power and water professionals, including utility heads from Nigeria, Uganda, Namibia, Senegal, Ghana, Malawi, Tanzania, Zambia and South Africa, will gather for the 14th annual African Utility Week and Clean Power Africa conference and expo at Cape Town s CTICC from May. It is the largest utility gathering of its kind on the continent with visitors from 30 African countries and 70 worldwide. The expo will focus on the latest technology and services in the industry disciplines of metering, clean power, water, large power users, investment and finance, transmission and distribution, smart grids and generation. To assist utilities and large power users become more energy efficient and explore renewable energy options, African Utility Week has also teamed up with professional industry bodies for a varied series of free CPD-accredited technical workshops in electrical engineering, energy efficiency and renewable energy taking place on the expo floor. Find technical solutions to develop a maintenance road map South African municipalities care for infrastructure valued at R1 156 trillion. According to a report by the Financial and Fiscal Commission, there is a need for R80 bn over 11 years to address the current maintenance backlog in electricity, water and sanitation infrastructure and to return it to optimum condition. Find out how physical asset management can contribute to long term business success. Visit the SAAMA Pavilion at the 14th annual African Utility Week and Clean Power Africa ( to discover how asset management can be a key contributor to your long-term business success. Get advice on how to establish, maintain and improve common standards of maintenance in your organization. Don t miss the opportunity to discover thousands of solutions and technologies that can save your organization operational costs and improve your every-day work life. African Utility Week is the singular mustattend event for the power and water utilities industry in Africa. You can choose from a multi-track program offering inside expertise and get return on investments from the solutions and technologies presented. You can meet the industry experts that have the answers to a better-run business. We ve

37 gathered together an industry-elite group of real-world doers to share their expertise from grid to socket on best practices for effective power supply. In-depth knowledge focus days With the pre-conference focus days and on-the-floor seminars hands-on training for participants is offered. Find out about tested solutions and techniques from the industry s leading experts. Gain perspective through strategic keynote addresses focusing on the state of the industry as well as emerging trends. Practical applications To add a third dimension to the conference experience and gain on the ground knowledge in areas normally restricted from public access to bench-mark best practices in the industry, delegates may attend one of the popular post-event Site Visits, exclusive to African Utility Week. For more information regarding the conference program or to submit a paper, contact Claire Volkwyn, claire.volkwyn@ spintelligent.com, ; or go to z The Ecograph T RSG35 has a high resolution, large display Record, visualize and monitor as every measurement value counts! The new Universal Data Manager Ecograph T RSG35 from Endress+Hauser guarantees a safe and complete recording and visualization of all process steps, to fulfill the demands on process monitoring and data recording that are becoming more and more complex as every measurement value counts! Simple operation Clear presentation The Ecograph T RSG35 has a brilliant, high resolution 5,7 large display. This allows the recorded measurement values, which can be indicated in groups up to 4 with a maximum of 8 channels for each group. Flexible measurement value indications such as curve, waterfall, bargraph or digital value extend the application areas of the RSG35. We understand that flexibility is important and with the ability to adjust the visualization to the application and the customer requirements. The operation of the device is based on the intuitive concept of the navigator known from the Advanced Data Manager, Memograph M. To ease the operation of the Ecograph T RSG35 there is an integrated online help and the possibility to connect an external USB keyboard. Informative and Intelligent New integration possibilities have also been implemented in the standard device. For further calculations, four virtual math channels are available as an option. These can be used for individual calculations that can be entered simply via the formula editor. An easy function that enables a notification in case of limit value infringements, errors, alarms and low/high signals of the digital inputs facilitate a enhanced process overview. Secure and Versatile The Ecograph T RSG35 is the simple solution for a tamperproof recording of data, with up to 12 universal analog inputs available. With its additional 6 digital inputs, other values like quantities, runtimes and switching states of connected devices can be captured or a time synchronization can be done. The recorded measurements are stored in the 128MB large internal memory and optionally on SD card as well. Due to modern interfaces like Ethernet in the standard device and communication protocols like Modbus TCP/RTU the device can smoothly be connected to existing systems. Up to 30 limit values can freely be assigned to the channels. Limit value changes are displayed and stored in the device. Furthermore 6 internal relays can be switched for the alarm transmission. For the readout, storage and graphic presentation of the measurement values, the free-of-charge Essential version of the Field Data Manager software is included in the delivery package of the Ecograph T RSG35. Based on an SQL database data can be read out tamper-proof from the device, either from the internal device memory or from the SD card, using the various interfaces available, stored and centrally managed. Different visualization possibilities make the stored data transparent. The user is automatically led through the software by individual operation steps which guarantee an intuitive operation with a simple and fast report generation. A software upgrade to the Professional Version is possible at any time using a license package and without the need of a reinstallation.the robustness of the Ecograph T has been improved with a zinc diecast front that increases the IP class to IP65 as well as makes the device in general even more robust. Enhanced web server Worldwide access The completely reworked integrated web server enables access to current and historic process data via conventional standard web browser, without the need for additional software when and where it is required. Via the web server the data can be indicated through remote access/control in the same way as on the device and diagnostic information can be recalled. Three user levels with different user rights on the device protects against unauthorized access and the safety of the data is ensured. The new Ecograph T RSG35 is the cost-effective solution for all applications in which process parameters have to be recorded and monitored. Thereby the device offers maximum ease of use and system capability at a perfect priceperformance-ratio! For more information contact Benjamin Mlangeni on tel: , or info@za.endress.com. z etc 35

38 etc The KoelnMesse conference centre in Cologne Call for Papers for FILTECH 2015 FILTECH 2015 will take place from February 2015, when, as a result, the City of Cologne in Germany will turn into the top meeting-place for all those involved with filtration and separation and adjacent sectors. FILTECH, considered the world s largest filtration show, will take place for the first time at a new venue called the KoelnMesse. The FILTECH Congress made up of more than 200 presentations, will offer a representative cross section of current research findings, global developments, and new approaches to both filtration and separation. Special highlights are a plenary lecture and six survey lectures in which internationally renowned experts will give a comprehensive overview of state of the art knowledge and techniques concerning important aspects of separation technology. Abstracts can be submitted until July 4, Details for abstract submission and stand booking are available at A Conference for Producers and Suppliers operating in the African Gas Industry Date: Tuesday 26th to Wednesday 27th August Venue: The Radisson Blu Gautrain Hotel, Sandton, Johannesburg, Gauteng The 2014 Gas Africa Conference will expose you to some of the top industry minds and allow you a great opportunity to not only learn from them, but to interact with them and your peers, to you and your company s ongoing benefit! Normal price is R6 000 incl vat, per delegate. APA members pay a reduced fee of R5 500 incl VAT. These prices include all refreshments and lunch on both days of the conference. To book, or if you have any questions, please contact Jody Cairns at or at jody@mcnaughtonevents.co.za. z Have you visited our website today? SUDOKU NO. 92 Complete the grid so that every row across, every column down and every 3x3 box is filled with the numbers 1 to 9. That s all there is to it! No mathematics are involved. The grid has numbers, but nothing has to add up to anything else. You solve the puzzle with reasoning and logic. For an introduction to Sudoku see en.wikipedia.org/ wiki/sudoku Solution for SUDOKU 91 36